MSC Manifolds - ASTM for Steam Distribution and

1170050/5
IM-P117-03
ST Issue 5
MSC Manifolds - ASTM
for Steam Distribution and Condensate Collection
Installation and Maintenance Instructions
1. General
safety information
2. General
product information
S
P
I
R
A
X
S
A
R
C
O
3. Installation
4. Commissioning
5. Operation
6. Maintenance
MSC04 shown
IM-P117-03
Printed
in theST
UKIssue 5
7. Spare parts
1
© Copyright 2002
1. General safety information
Safe operation of the unit can only be guaranteed if it is properly installed,
commissioned and maintained by a qualified person (see Section 11 of the attached
Supplementary Safety Information) in compliance with the operating instructions. General
installation and safety instructions for pipeline and plant construction, as well as the proper
use of tools and safety equipment must also be complied with.
Warning
The graphite stem sealing rings contain thin stainless steel support rings which may
cause physical injury if not handled and disposed of carefully.
Isolation
Consider whether closing isolating valves will put any other part of the system or personnel
at risk. Dangers might include; isolation of vents and protective devices or alarms.
Ensure isolation valves are turned off in a gradual way to avoid system shocks.
Pressure
Before attempting any maintenance consider what is or may have been in the pipeline.
Ensure that any pressure is isolated and safely vented to atmospheric pressure before
attempting to maintain the product, this is easily achieved by fitting Spirax Sarco
depressurisation valves type DV (see separate literature for details). Do not assume
that the system is depressurised even when a pressure gauge indicates zero.
Temperature
Allow time for temperature to normalise after isolation to avoid the danger of burns and
consider whether protective clothing (including safety glasses) is required.
Disposal
The product is recyclable. No ecological hazard is anticipated with the disposal of this
product providing due care is taken.
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2. General product information
2.1 General description
A range of forged carbon steel compact manifolds with integral piston type stop valves for steam
distribution and condensate collection duty. MSC manifolds can be used for either steam
distribution duty or condensate collection duty depending on the way they are installed. They are
supplied with EN 10204 3.1.B certification as standard for the body and yoke.
Note: For additional information see the following Technical Information Sheets: TI-P117-02 and
TI-P117-23.
2.2 Available types, sizes and pipe connections
MSC manifolds are available with 4, 8 or 12 connections designated MSC04, MSC08 and MSC12
respectively and flanged BS 1560 (ANSI) class 150 or 300 or socket weld to ANSI B 16.11
Class 3000 or screwed BSP or NPT.
The steam main /condensate return connection is DN40.
The tracer line and drain connections are available as DN15, DN20 flanged, screwed BSP, NPT
and SW to ANSI B 16.11. The DN25 is available with flanged connections only.
2.3 Optional extras
The following are available at extra cost:
- Mounting kit comprising of studs, spacers and nuts.
- Insulation jackets for body and flanges.
Alternatives
Flow direction when used
for steam distribution duty
Flow direction when used for
condensate collection duty
Fig. 1 Type MSC04 socket weld version shown
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2.4 Limiting conditions
Body design conditions
ANSI Class 300
ISO PN50
Design for a maximum
cold hydraulic test pressure of:
ANSI Class 150
30 bar g
(435 psi g)
ANSI Class 300
76 bar g
(1 102 psi g)
Temperature °C
2.5 Operating range
425
A
300
200
100
0
C
0
10 14*
Steam
saturation
curve
20
30
Pressure bar g
B
40 41.5*
51
The product must not be used in this region.
* PMO Maximum operating pressure for steam service.
A - B Flanged ANSI Class 300, screwed and socket weld.
A - C Flanged ANSI Class 150.
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3. Installation
Note: Before actioning any installation observe the 'Safety information' in Section 1.
Referring to the Installation and Maintenance Instruction, name-plate and Technical Information
Sheet, check that the product is suitable for the intended installation:
3.1
Check materials, pressure and temperature and their maximum values. If the maximum
operating limit of the product is lower than that of the system in which it is being fitted,
ensure that a safety device is included in the system to prevent overpressurisation.
3.2
Determine the correct installation situation and the direction of fluid flow.
3.3
Remove protective covers from all connections.
Note: If the trap draining the manifold is to discharge to atmosphere ensure it is to a safe place,
the discharging fluid may be at a temperature of 100°C (212°F).
3.4 General information
The manifold has been designed for vertical installation. Ensure that there is sufficient access to
the handwheel to allow proper operation. The back is provided with threaded connections M12
for attaching to a supporting structure.
For ease of insulation it is recommended that spacers are fitted to give the manifold a stand-off
of at least 50 mm.
For convenience the following sets of mounting kit are available:
- A single set comprising 2 off each stud, nut and spacer suitable for installing one MSC04
or MSC08.
- A single set comprising 4 off each stud, nut and spacer suitable for installing one MSC12.
- A multiple set comprising 12 off each stud, nut and spacer suitable for installing 6 x MSC04,
6 x MSC08 or 3 x MSC12.
After installation it is recommended that the manifold is insulated to minimise radiated heat
losses and to protect personnel from burn risks. This is most easily done using the optional
insulating jacket.
Spacer
M12 nut
MSC manifold
M12 stud
50
mm
Structural steelwork
Fig. 2 Installation view from underneath
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3.5 Steam distribution duty
The recommended installation is with the steam inlet connection at the top of the manifold. A trap
set should be fitted to the bottom. The discharge from this trap set should ideally be returned. If it
is to be discharged to atmosphere we recommend that a diffuser is fitted.
3.6 Condensate collection duty
The recommended installation is with the condensate outlet at the top. The bottom of the
manifold should be fitted with a stop valve for blowdown purposes. Again, we recommend that
a diffuser is fitted.
3.7 Pipeline welding
A universal weld procedure covering the requirements of different National and International
Standards and practices is difficult to provide - specifically regarding the welding procedure,
welding conditions (run number, consumable size, current, voltage, polarity), storage of consumables
and make/type of consumables due to the abundance of appropriate consumable suppliers.
Therefore, this is only advice based on British Standards to be used for guidance on the essential
requirements of welding socket weld manifolds into the pipeline. This will allow a user to select an
appropriate weld procedure from those available to that user. This advice is not intended to be
a substitute for a weld procedure: it is for guidance only.
The welding of manifold DN15, DN20 and DN40 socket weld
to 15 mm, 20 mm and 40 mm Schedule 80 pipe
Parent material(s)
Description
Carbon steel with minimum tensile strength
up to and including 430 N / mm²
Parent material(s) dimensions
Specification(s)
ASTM A105N (MSC)
ASTM A106 Gr. B (Pipe)
Material group(s)
A1
DN15
Thickness (mm)
O/D (mm)
DN20
DN40
MSC
Pipe
MSC
Pipe
MSC
Pipe
8.25
35.50
3.73
21.30
5.50
35.50
3.91
26.70
7.0
65.0
5.0
48.3
Pipe is to be BS 1600 Schedule 80
Joint type ANSI B 16.11
Socket joint to Class 3000 lb (this is equivalent to BS 3799)
Weld preperation
Welding process
Dimensioned sketch
Manual Metal Arc (MMA)
Diametrical clearance 1.0 mm maximum
Welding position(s)
All: Site welded
MSC
t
Pipe
1.5 mm approximately
Reference - BS 2633: 1987: Section 3.1 and Fig. 9
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4. Commissioning
After installation or maintenance ensure that the system is fully functioning. Carry out tests on
any alarms or protective devices.
5. Operation
The integral piston valves should be either fully open or fully closed. They are not intended for
throttling duties. The rising stem of the integral piston valves provides an indication of the amount
of valve opening.
During closing operation the piston ensures a permanent seal by means of the handwheel.
Therefore during service never remove the handwheel from the spindle. Due to the large sealing
area of the piston valve, it is not necessary to use a valve key to ensure leaktight shut-off.
During opening operation the piston is stopped when the valve is fully open as its top touches
the inside of the bonnet.
Operation of the handwheel should always be light.
6. Maintenance
Note: Before actioning any maintenance programme observe
the 'Safety information' in Section 1.
Warning
The graphite stem sealing rings (items 2 and 3) contain thin stainless steel support rings
which may cause physical injury if not handled and disposed of carefully.
6.1 Maintenance in service
After the manifold is first put into service or after a change of sealing rings (2 and 3), the
yoke nuts (11) should be lightly followed up with the valve in the closed position. Ensure the
yoke (9) is driven down straight during tightening and that care is taken with the handwheel
operation. This operation is to be repeated should any trace of leakage develop. If perfect sealing
cannot be acheived in this way, repack the valve following the procedure below.
A small diameter hole evident in the valve yoke is primarily to prevent pressurisation within
the yoke, but is useful for observing leaks past the upper sealing ring and for lubrication of the
spindle (6) when the valve is closed.
6
11
Fig. 3
View showing valve internals
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3
2
7
6.2 Preparation of valve dismantling
Before starting work ensure that you have suitable tools and / or consumables available. Before
attempting to carry out any maintenance, ensure that the manifold is fully isolated and safely
depressurised. Do not assume the system is depressurised even when the pressure gauge
indicates zero. If performing maintenance whilst the pipework is hot, wear appropriate protective
clothing. Carefully remove insulation if fitted. When using the optional insulation jacket, this is
easily removed by undoing the fastenings.
6.3 Dismantling the valve:
- Using the handwheel (7), fully open the valve.
- Remove the yoke nuts (11) and washers (12) from studs (10).
- Carefully turn the handwheel in the closing direction to lift the yoke (9).
- Rotate the yoke (9) to ensure that the flange bolt holes are misaligned with the studs (10).
- Turn the handwheel in the opening direction to release the piston (5) from the sealing
-
rings (2 and 3) and so release piston / yoke sub-assembly from the body.
The piston (5) is attached to the spindle (6) using a ball and socket joint as supplied, therefore
they should never be separated.
Examine the piston (5) for signs of scoring, corrosion etc., which could affect perfect tightness
of the valve.
Check other parts for wear / damage and replace if necessary.
6.4 Repacking the valve:
- With the valve dismantled, insert the valve internals extractor tool through the sealing rings
-
(2 and 3) and lantern bush (4).
Firmly tap to ensure that the tool bottoms out in the bore and with a quarter turn of the handle
carefully remove the two sealing rings (2 and 3) and the lantern bush (4).
Thoroughly clean the sealing ring housing and all the internals.
Fit new lower sealing ring (2), lantern bush (4) and new upper sealing ring (3), ensuring they fit
perfectly. (Note: The lower and upper rings are the same).
Apply a thin layer of graphite based grease to threads only (not to internals and piston).
6.5 Reassembling the valve:
- Take the piston / yoke sub-assembly and turn the handwheel (7) in the opening direction up
-
to the stop.
Insert piston (5) into the upper sealing ring and push it down until it is possible to fit washers (12)
and screw yoke nuts (11) onto the studs (10) and then hand tighten.
Shut the valve fully, ensuring that the yoke (9) is driven down straight, gradually tighten
the yoke nuts (11) to the receommended torque (see Table 1).
Replace any insulation.
Table 1 Recommended tightening torques
or
Item
Nm
(lbf ft)
0.1
(0.07)
10.0
(7.50)
mm
8
8
8 A /F
11
14 A /F
M5
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6
10 11 12
8
Fig. 4 View showing valve internals
9
3
4
2
5
Extractor tool
Fig. 5 View showing valve internals extractor tool
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7. Spare parts
The spare parts available are detailed below. For ease of replacement an extractor tool is
available for removing the sealing rings.
Available spares
Sealing ring set
Sealing ring set
Lantern bush
Valve internals set, consisting of:
Piston with spindle
Handwheel nut
Washer
Extractor tool
Mounting kit
2, 3
2, 3
4
5, 6
8
13
see Fig. 5, page 9
see Section 3.4, page 5
How to order spares
Always order spares by using the description given in the column headed 'Available spares' and
state the size and type of manifold.
Example: 1 - Sealing ring set for an integral piston valve on a carbon steel manifold MSC04
DN15 socket weld.
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Alternatives
Flow direction when used
for steam distribution duty
Flow direction when used for
condensate collection duty
2
4
3
6
8
13
Fig. 6 Type MSC04 with socket weld connections shown
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